Analyzers and Process InstrumentationAnalyzers and Process Instrumentation

Measurement Technology Tailored to Your Needs – for Efficient Process Control and Precise Emission Monitoring

Gas Analyzers and Analysis Systems

ProduC t ovErviE w

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Practice-oriented solutions using our gas analyzers and tailored to the requirements of individual branches of industry realize the widest range of measuring tasks, worldwide.

Single measuring devices or complete analysis systems – from process control to emission monitoring – SICK MAIHAK stands for sophisticated in-situ and extractive measuring technology. Applications in cement, steel or power generating plants or also in the chemical industry – different requirements demand adaptability on the basis of specifications (EU, EPA or GOST). The industry solutions from SICK MAIHAK comply with legal specifications, are adapted to the respective plant conditions and provide maximum flexibility in gas analysis.

In addition, a comprehensive selection of accessories is available – from the single, unheated sampling probe, the

industry solutions from SiCK MAiHAK:From single-component analyzers to turnkey analysis systems

EMiSSion MonitorinG

Pollutant reduction, meeting limit values, compliance with environmental regulationsPollutants in exhaust gases must be determined online and with precision. Official and company-internal require-ments are complied with reliably and with reasonable effort. For this purpose, we offer analyzers with approvals according to European Directives, for example, the 2001/80/EC, 2000/76/EC as well as EPA or GOST certifi-cation.

CEMEnt induStry

Production process optimization with gas analysis, reliable electric filter monitoringIn cement works, continuously measuring analyzers are required in many stages of the production process, whether for process optimization, saving energy or safety monitoring. The operational reliability of the SICK MAIHAK analysis systems is maintained even at high temperatures.

applicable gas conditioning up to the complete gas extrac-tion system for very high temperatures and dust loads.

SICK MAIHAK – this means:High-quality measuring systems for gas analysis as well • as emission data evaluation systemsReliable measurement of dust and volume flow• Tailored applications with in-situ and extractive measur-• ing technologyComplete projects – from basic engineering to after-• sales serviceTop technological quality• Measuring principles proven over many years•

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PowEr PlAntS

Efficient flue gas monitoring, effective denitrification process control and combustion process optimizationFor optimum operation of a power plant – from the coal bunker to flue gas evacuation to the atmosphere – the concentration of gas components must be monitored. Coal combustion not only creates solid residues (slags, ashes) and dust but, above all, gaseous compounds demanding continuous concentration determination.Typical applications:DeNOx denitrification plant, flue gas desulphurization plant, emission monitoring, optimization of combustion processes (CO, CO2, O2)

tHErMAl wAStE trEAtMEnt

Compliance with strict limit values In many countries, thermal waste treatment plants are subject to strict emission regulations. Suitable measures (flue gas purification) and sturdy measuring technology have to ensure that pollutants in the plant exhaust gas do not exceed allowed limit values.Typical applications:Analysis of CO, SO2, NO2, HCl, HF, mercury emissions, flue gas purification, VOC

CHEMiCAl induStry

Flexible analysis device adaptation to the respective processThis branch of the industry is characterized by complex process engineering, a high degree of automation and a great variety of products. Chemical production processes require safe procedures on the basis of sophisticated and reliable technologies. Very specific adaptation of the ana-lytics to the measuring task is an integral part of these pro-cesses.Typical applications:Production of sulphuric acid, nitric acid, phosphoric acid, in the glass industry and production of synthetics

MEtAllurGy

reliable gas concentration monitoring and continuous pollutant emission acquisitionIn iron and steel production, the analysis of furnace gas or reformer gas is important. In addition to process gas moni-toring, safety monitoring (CO measurement, inertization) and pollutant emission control play an important role.Typical applications:Oxygen furnace, ore calcination (metallurgy), HF monitor-ing (aluminium production), inertization of metal mills

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No sampling• Continuous, direct • measurement without lag times in processesVery low reaction times• Very low maintenance • effort

Representative mea-• surement – using cross-duct technology across the complete channel cross-sectionQAL3 function accord-• ing to DIN EN14181

Advantages of in-situ measuring technology

in-Situ MEASurinG tECHnoloGy

For quick gas analysis, analyzers are available as complete devices to determine the sample gas components “in-situ”, i.e. directly at the measuring location.

The following measuring principles are used, among oth-ers:

UV spectrometry (DOAS)• IR filter correlation• Laser spectroscopy (TDLS)• Zirconium dioxide measuring principle•

The correct answer to complex requirements

to adapt to different plant conditions or to solve complex measuring tasks, we have the answer: in-situ and/or extractive measurement by SiCK MAiHAK

tailor-made service:We provide complete service – ranging from project plan-ning and implementation of analysis equipment up to walk-in, turnkey containers. SICK MAIHAK is represented worldwide with technical competence for planning, installa-tion, start-up and maintenance of measuring devices and systems. This makes SICK MAIHAK a competent local part-ner for users in every aspect.

In-situ analyzerAdapted technology:

Cross-duct technology: Representative measuring • results across the complete channel cross-sectionProbe technology: For complicated measuring tasks, for • example overpressure, “wet” gases or very high sample gas concentrations

In-situ analyzer in probe design

Differential Optical Absorption Spectroscopy (DOAS)

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Optimal analyzer confi-• guration options for versatile applicationsAdapted solutions due • to a multitude of mea-suring components

Precise measuring • results through proven measuring principlesDetection of aggres-• sive, corrosive or com-bustible gasesQAL3 function accord-• ing to DIN EN14181

Advantages of extractive measurement

Efficient standard • systems for emission-typical applicationsSystems configured • according to customer specifications for many process applications

Simple retrofitting, • simple installation and start-upCompact and sturdy • designQAL3 function accord-• ing to DIN EN14181

Advantages of the systems

EXtrACtivE MEASurEMEnt

With extractive gas analysis, the analyzers identify numer-ous gas components, for example SO2, NO, NO2, CO, CO2, O2, HCl, HF, NH3, H2O, mercury, hydrocarbons, and total car-bon.

The following measuring principles are used:NDIR and UV photometry• Flame ionization detection• FTIR spectroscopy• Paramagnetic, electrochemical principles• Single-beam bifrequency process (filter correlation)• Cold-vapor atomic absorption spectroscopy•

AnAlySiS SyStEMS

Apart from our versatile product range with individual and multicomponent analysis systems, we also offer compre-hensive application experience in different industries. Tailor-made concepts are available in addition to standard solutions. Each proposal is oriented to the local require-ments and situations. Here we develop specific solutions – precise, fast and cost-efficient. Above and beyond the system components, we plan complete gas analysis sys-tems, for example turnkey analysis cabinets including all peripheral equipment.

Extractive analysis system

Extractive analyzer on the basis of the NDIR principle

Probe

Sampling line

Analyzer

System cabinet

S710

S715S720

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Technical DaTa

S700 SeRieSnDiR GaS analYZeR4 cOMPOnenTS MaX.

SiDORnDiR GaS analYZeR2 iR cOMPOnenTS PlUS O2

Measuring principle nDiR absorptionParamagnetic/electrochemical (O2)Interference filter correlationThermal conductivity

nDiR absorptionParamagnetic/electrochemical (O2)

Measuring components CO, CO2, SO2, NO, NH3, H2O, N2O, CH4, C2H2, C2H4, C2, H6, C3H6, C3H8, C4H6, C4H10, C6H14, O2 and many more

CH4, CO, CO2, NO, SO2, O2

Measuring task Emission and process monitoring

Standard equipment with up to 3 analyzer modules possible. 6 different analyzer modules are available for analyzing more than 60 gas components.

Single or simultaneous measurement of up to4 components

Emission and operational applicationsCombustion optimization of small boilers

Single or simultaneous measurement of up to 2 IR gas components and, additionally, oxygen using auxiliary modules

Landfill and biogas monitoring (ATEX)

Advantages Extremely compact analyzer• Explosion-protected version optional• Fully automatic measuring mode• Low maintenance, easy to use• Flexible configuration options through a variety of • analog/digital interfacesMonitoring of external status signals•

Low test gas consumption (feeding > 6 months) • with a long term stable measuring cellHigh selectivity and measuring sensitivity• Automatic readjustment with component-free • ambient airSimple maintenance, can be repaired locally• High availability by local service•

Compliance, regulations TA Luft, 2001/80/EC, 2000/76/EC, 27th FICA (Federal Immission Control Act), MCERTS, GOST

TA Luft, 2001/80/EC, 27th FICA (Federal Immission Control Act), ATEX type certificate for measuring CH4, CO2 and O2

Measuring location

Model Enclosure S710: • Comfortable 19" housing, easy to handleEnclosure S715: • Easy to install wall housing, also for usage in explosion zone 2Enclosure S720 Ex: • Pressurized housing for usage in explosion zone 1

Comfortable 19" mounting•

Maintenance, repairs

With filter cuvette (option), calibration possible • (only IR)Low effort• Able to fulfill QAL3 regulation•

Calibration possible with ambient air, test gases • required only every half yearLow effort• Able to fulfill QAL3 regulation•

Cleaning Simple housing care Simple housing care

Gas analyzersmulticomponents

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McS100MUlTicOMPOnenT analYZeR

GM35MUlTicOMPOnenT analYZeR

GM31MUlTicOMPOnenT analYZeR

Single-beam photometryBifrequency and gas filter correlation

Filter correlation (iR)Gas filter correlation

Transmission UV spectroscopy (differential optical absorption spectroscopy)

UV/VIS/(N)IR absorbing gases and liquids CO, CO2, H2Opressure, temperature

SO2, NO, NH3 respectively NO2

pressure, temperature

Process analysis of gases/liquids under harsh conditions

Up to 8 measuring components can be mea-sured and 4 disturbance variables per compo-nent can be offset simultaneously

For economic control of combustion processes and drying plants as well as emission monitoring

Simultaneous or single measurements

For emission measurement in flue gas desulphurization and denitrification plants

Simultaneous or single measurements

Cost-effective, very sturdy single-beam • photometerAutomatic correction of disturbance • variables Automatic measuring range switch-over with • limit monitoringAutomatic sensitivity monitoring• Flexible to use for sophisticated tasks•

Reliable, rapid and efficient• Easy to install, start-up and maintain• Internal temperature measurement• Calculated value output (mg/m• 3 in operating/standard state, ppm)

Reliable, rapid and efficient• Easy to install, start-up and maintain• Internal temperature measurement• Calculated value output (mg/m• 3 in operating/standard state, ppm)

EN 61010-1, EN 61326 TA Luft, 2001/80/EC, 2000/76/EC, MCERTS, GOST, U.S. EPA

TA Luft, 2001/80/EC, 2000/76/EC, MCERTS, GOST, U.S. EPA, Kaitec

Extractive modular system• Configuration with probe: • Installation from one sideCross-duct configuration: • Installation from both sides (opposite each other)

Probe configuration: • Installation from one side

Low effort• Minimum maintenance effort• Able to fulfill QAL3 regulation•

Minimum maintenance effort• Able to fulfill QAL3 regulation•

Simple housing care Cleaning of optical windows only:Intervals approx. 3 to 6 months

Cleaning of optical windows only:Intervals approx. 3 to 6 months

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Gas analyzerssingle components

Technical DaTa

GM700laSeR analYZeR

ZiRkOR302OXYGen analYZeR

eUROFiD TOTal hYDROcaRBOn analYZeR

Measuring principle laser spectroscopy (TDlS) Zirconium dioxide (current sensor)

Flame ionization detector

Measuring components NH3, HF, HCl, O2

pressure, temperatureO2 Total hydrocarbon (org. C)

Measuring task Rapid process analysis and emis-sion monitoring

Also available in a configuration for the automotive industry for O2 or NH3 measurement

Optimizing industrial combustion processes and calculation of reference values

Continuous measurement of organic compounds in corrosive and condensing gases

Usable for process temperatures up to 600 °C as well as in trace concentrations up to 100 percent by volume

Advantages Compact system without • moving partsHigh spectral resolution• Wave length stability• No calibration necessary • Gas test possible • (with gas diffusion probe)

Extendable: Up to three O• 2 analyzers can be connected to one evaluation unitShort response time for pro-• cess controlAir as reference gas• No mechanical sample gas • pump necessaryTemperatures up to 1400 °C•

No wear and tear due to • moving partsIntegrated sample gas dilution• Overpressure method for mini-• mum errorsExplosion protected version • zone 1, EU type approval for LEL monitoring

Compliance, regulations 2000/76/EC in preparation (HF, HCl)

TA Luft, 2001/80/EC, 2000/76/EC, MCERTS, GOST, U.S. EPA

TA Luft, 2000/76/EC, MCERTS, ATEX

Measuring location

Model Configuration with probe: • Installation from one sideCross-duct configuration: • Installation from both sides (opposite each other)

Probe configuration: • Installation from one side

Wall fitting configuration for • plate assemblyInline configuration for direct • channel installation

Maintenance, repairs

Minimum maintenance effort• QAL3 function in preparation•

Very low effort• No expandable materials• Able to fulfill QAL3 regulation•

Low effort • (replacement of gas filter)Able to fulfill QAL3 regulation•

Cleaning Cleaning of optical windows only: Intervals of approx. 3 to 6 months

Intervals approx. 3 to 6 months Simple housing care

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FiD3006 PORTaBle TOTal hYDROcaRBOn analYZeR

GM901 caRBOn MOnOXiDe analYZeR

GM950RaPiD, ReDUnDanT cO MeaSURinG SYSTeM

Flame ionization detector Gas filter correlation Zirconium dioxide with electrical cell

Total hydrocarbon (org. C) CO CO (equivalent): COe = CO+H2+CxHy)

Flexible use for measuring organic substances

Compact, portable unit for flexible use. Measurement of organic substances even at measuring points difficult to access.

Monitoring of combustion plants

For difficult measuring tasks (high dust loads, overpressure, “wet” flue gases, extremely high gas concentrations)

Detection of unburned components in exhaust gases.

Monitoring electric filters for high CO values

Automatic fuel gas switch-off when flame • extinguishesPrecise measurement through patented • analysis chamberLow fuel gas consumption• Low operational costs• Short warming up time•

Fast and simple installation and start-up• Simple operation directly on the evaluation • unitMeasured value, measuring range and limit • value can be read off directlyVery low maintenance requirements•

Very short reaction time (t • 90 <2 sec.)Usage for dust loads up to 200 g/m• 3 and gas temperatures up to 500 °CHigh availability through redundant sensors• Maintenance of single system components • during measuring operation possible

TA Luft, 2nd FICA (Federal Immission Control Act), 2000/76/EC, MCERTS, UL, CSA

GOST, U.S. EPA (measuring probe configuration)

Inline measurement direct at measurement location

No mounting – mobile device• Configuration with probe: • Installation from one side Cross-duct configuration: • Installation from both sides (opposite each other)

Low effort (replacement of gas filter)• Able to fulfill QAL3 regulation•

Minimum maintenance effort• Low effort•

Simple housing care Cleaning of optical windows only:Intervals approx. 3 to 6 months

Visual device inspection (approx. every 4 weeks)

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Analysis systems

Technical DaTa McS100FTMUlTicOMPOnenT analYSiS SYSTeMMORe Than 10 cOMPOnenTS

McS100e, McS100e-hW/cD/PDMUlTicOMPOnenT analYSiS SYSTeMMORe Than 10 cOMPOnenTS

Measuring principle FTiR spectroscopy Single-beam photometer, bifrequency and gas filter correlation method

Measuring components Simultaneously >10 IR absorbing gas components plus O2 as well as org. C (optional)

Simultaneously max. 8 IR absorbing gas components plus O2 and org. C

System components (typical) FTIR analyzer• Heated measuring gas cell• Electronics• IO modules• System control unit for operation• FID unit (optional)•

MCS100E: compact analyzer in a housing• MCS100E system in a cabinet: •

Sample gas transportation and conditioning –(sample gas cooler/permeation dryer, pump)MCS100E analyzer –Temperature control –FID (optional) –

Application Actual monitoring of the strict HF limit values (0 … 3 mg/m3; 4 ppm) according to 2000/76/EC

One analysis system for independent emission monitoring – designed to meet almost all emission directives

Flue gas monitoring

MCS100E system with the configurations:MCS100E-HW with high-temperature measuring • technology for waste incineration plantsMCS100E-PD with gas dryer to record extremely • small measuring rangesMCS100E-CD with gas cooler for power station•

Advantages Very sturdy analysis system based on standard-• ized system technology according to the high-temperature measuring technologyMulticomponent analysis system (>10 measuring • components simultaneously)Usage of state-of-the-art FTIR technology with • new generation industrial spectrometer

Up to 8 gas components and additional • O2 measurement (optional) plus org. C measurement (optional)Automatic zero and test gas feeding• Reliable, proven systems• Very low maintenance requirements• Several measuring points with one system• QAL3 function (able to fulfill QAL regulation)•

Compliance, regulations TA Luft, 2001/80/EC, 2000/76/EC, MCERTS, U.S. EPA, GOST (in preparation)

TA Luft, 2001/80/EC, 2000/76/EC, MCERTS, U.S. EPA, GOST

Measuring locationMaintenance Low effort•

QAL3 function in preparation• Low effort• Able to fulfill QAL3 regulation•

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MkaS MODUlaRMUlTicOMPOnenT analYSiS SYSTeM

MkaS cOMPacTMUlTicOMPOnenT analYSiS SYSTeM

MeRceMMeRcURY analYSiS SYSTeM

Depending on the built-in analyzer (S710, SiDOR)

Depending on the built-in analyzer (S710, SiDOR)

cold-vapor atomic absorption, photometry

Depending on the built-in analyzer, for example:CO, NO, SO2, CO2, H2, CH4, O2 and others

Depending on the built-in analyzer, for example:CO, NO, SO2, CO2, CH4, O2

Hg

Analyzer(s) (S710 or SIDOR)• Sample gas cooler• Sample gas pump• Sample gas lines• Heat controller• Pumps, filter, precipitator, valves• Data acquisition and processing system•

Analyzer (S710 or SIDOR)• Gas cooler (1-stage)• Sample gas pump• Heat controller•

Sample gas pump• Analyzer • Sample gas conditioning• System control unit•

Standard system for emission monitoring

The MKAS MODULAR can be optimized with a number of proven options to meet almost all plant conditions.

A complete, very compact analysis system

Compact and intelligent integrated cabinet so-lution for the installation of a standard analyzer (19", 3 HU)

Continuous flue gas monitoring of mercury (total Hg)

As independent system or in combination with a MCS100E- HW

Switch-over of measuring locations• Can be equipped optionally with emission • value computerFlexible application, simple retrofitting • through modular conceptSimple installation and start-up•

Effective price/performance ratio • Very economic due to favorable purchasing • costs and low maintenance effort

Detection of elemental and bound mercury• Very low detection limits• Very low cross-sensitivity• Automatic sensitivity monitoring (option)•

Depending on the built-in analyzer Depending on the built-in analyzer TA Luft, 2000/76/EC, MCERTS, US EPA

Minimum maintenance effort• Low effort•

Minimum maintenance effort• Low effort•

Low effort• Able to fulfill QAL3 regulation•

Analyzers and Process Instrumentation

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w E o F F E r yo u A C H o i C E

SICK MAIHAK offers a number of sensor-based techniques for anal-ysis, ranging from the continuous gas and dust measurement to specialized applications for water and liquid analysis. Within the process measurement technol-ogy SICK MAIHAK products play a central role in determining volume flow of gases and level of bulk materials.

A r o u n d t H E w o r l d t o yo u r S E r v i C E

Whereever you are, our global network of subsidiaries and rep-resentatives is able to supply qualified support when you need it. We deliver the equipment for your measuring tasks, provide documentation and training. Our highly skilled service staff offers support during installation, com-missioning and maintenance of the appliances.

SiCK GrouP

SICK MAIHAK represents the process automation segment of the SICK group, one of the worlds leading manufacturer of intelligent sensors and sensor solutions. With its 4,000 employ ees, SICK offers an ex-ten sive portfolio of products and services on the market of factory and process automation.www.sick.com

At H o M E i n t H E i n d u S t r i A l S E C t o r

We can build on years of experi-ence in the field of Analyzers and Process Instrumentation. That is why we are at home in the world of cement and power plants as well as in the chemical and pet-rochemical sector. Be it emission control at the waste treatment or process optimization for steel manufacturing, SICK MAIHAK offers tailor-made solutions.

A n A ly z E r S A n d P r o C E S S i n S t r u M E n tAt i o n

SICK MAIHAK GmbH | Analyzers and Process Instrumentation Nimburger Str. 11 | 79276 Reute | Germany | www.sick-maihak.com Phone +49 7641 469-0 | Fax +49 7641 469-1149 | info.sick-maihak@sick.de